Method of making expansion joints



March 17, 1953 J. P. ZALLEA METHOD OF MAKING EXPANSION JOINTS Filed Dec. 10, 1948 3 Sheets-Sheet l iNVENTOR JAMES F? 'ZA LLEA ATTORNEY March 17, 1953 J. P. ZALLEA 2,631,640

METHOD OF MAKING EXPANSION JOINTS Filed Dec. 10, 1948 3 Sheets-Sheet 2 INVENTOR 'JHMES F! ZHLLEA ATTORNEY March 17, 1953 J. P. ZALLEA METHOD OF MAKING EXPANSION JOINTS 3 Sheets-Sheet 5 Filed Dec. 10, 1948 Zhmenhzn:

GAMES P, Z'ALLEH attorney Patented Mar. 17, 1953 UNITED STATES PATENT OFFICE METHOD OF MAKING EXPANSION JOINTS James P. Zallea, Wilmington, Del.

' Application December 10, 1948, Serial No. 64,488

3 Claims.

This invention relates generally to expansion joints and more particularly to a method of making expansion joints having as a part thereof one-piece toroidal-shaped bellows elements.

It is a principal object of the present invention to provide a method of making expansion joints having thin-walled bellows elements which are capable of withstanding very high internal pressures, which are usable with the heavy gauge pipe necessary in a pipe line for such pressures and which permits a maximum of flexings before any failure due to material fatigue.

' Also among the principal objects ofv the present invention is to provide a method of making a one-piece thin-walled hydraulically bulged bellows elements capable of withstanding high internal pressures and a maximum number of flexings before failure due to material fatigue.

It is a further object of the present invention to provide a method of making toroidal-shaped bellows elements of one-piece construction which permits uniform flexing throughout the area of the bellows and which has no points of stress concentration which would reduce the number of flexings before failure of the bellows due to material fatigue.

It is also an object of the invention to provide a method of making expansion joints with one or more one-piece hydraulically bulged toroidalshaped bellows elements having integral tubular sections extending axially from opposite sides thereof, the method being accomplished without the use of f any restraining dies.

With the above objects in view, the invention further resides in the combination of steps, and the details thereof, herein described and claimed; it being understood that the specific embodiments of the invention described herein are illustrative and that modifications thereof falling within the scope of the appended claims will be apparent to persons skilled in the art.

In the drawings:

Figure 1 is a sectional view of a portion of a conventional hydraulic press showing in full lines the upper and lower platens with a cylindrical bellows blank positioned therebetween and in dotted lines an intermediate position of the platens and a partially formed bellows;

Figure 2 is a view similar to Figure 1 showing the lower platen in raised position with the toroidal-shaped bellows fully formed;

Figure 3 is a view similar to Figure 1 but showing a modified form of cylindrical bellows blank, the dotted lines showing the lower platen in raised position with the bellows fully formed;

Figure 4 is a sectional view of a bellows element formed in accordance with the present invention with pipe nipples encircling the integrally formed tubular sections of the bellows;

Figure 5 is a sectional view of a bellows element showing its integral oppositely extending tubular sections turned over flanges of an expansion joint adapted to be bolted to a pipe line or other equipment;

Figure 6 is a sectional view of a plurality of bellows elements welded to pipe nipples to form an expansion joint having a plurality of bellows;

Figure 7 is a sectional view of another modifled form of cylindrical bellows blank having an encircling band midway thereof;

Figure 8 is a sectional View of a pair of integral toroidal-shaped bellows as made from the blank shown in Figure '7.

Heretofore toroidal-shaped bellows elements for expansion joints have been formed from a pair of like hollow hemitoroidal-shaped blanks having their outer circumferential edges buttwelded together. The inner circumferential edges of these butt-welded blanks, axially spaced from each other, were usually secured to axially extending pipe sections by edge or fillet welding. The prior art bellows unit so produced thus comprised four separate members which when welded together to form a composite unit, was subject to certain decided disadvantages inherent in the welded construction.

Inasmuch as it was necessary for successful butt-welding of the outer circumferential edges of the hemitoroid members of the bellows that the wall thickness or gauge of the metal used be not less than a prescribed minimum, such prior construction of the bellows element necessarily involved the use of metal of such thickness as reduced the flexibility of the bellows and its flexing capability to less than that of a bellows made of thin gauge material. Furthermore, because there is a limit to the gauge ratio between the metals respectively forming the hemitoroids and the pipe sections for successful welding together of these metals, when the pipe sections were of relatively heavy gauge, as when they were of large diameter or designed for use under high internal fluid pressure, the metal of which the hemitoroid members were formed were necessarily of relatively heavy gauge, thus lmiting the flexing capability of the bellows element. Also, the weld lines betwen the hemitoroid members and the pipe sections, being directly in the regions of flex, produced points of stress concenwill be subject to uniform flexing throughout and V will be capable of a maximum number of flexings before failure due to material fatigue. Due to the absence of any lines of weld within the one-piece,

toroidal-shaped portion of the bellows element there are no points of stress concentrations therein, thereby permitting uniform flexing throughout the-bellows with no zones or areas of maximum or minimum flexing stress. H

It is well known that for a given metal the thinner its gauge the greater the number of flexings is it capable of withstanding before material failure. By the process of the present invention, the bellows element may beformed of the minimum wall thickness required for a given internal pressure thereof to thereby increase its flexing capability and consequently its useful life.

For purposes of illustrating the principles underlyin the present invention, the following practical examples may be given. Assumin the need for a corrugated expansion joint or bellows unit in a so inch diameter pipe line designed to withstand an internal pressure of 1000 pounds per square inch, the pipe line being formed of carbon steel and designed for a working stress of 11,000 pounds per square inch, the wall thickness ofthe pipe would be 1.36 inches according to the formula ffi S wherein Tp is the'pipe wall thickness, P is the working pressure, Rp is the pipe line radius and,

S is the permissible working strength of the carbon steel pipe. Employing. in conjunction with such pipe line e, stainless steel toroidal bellows" circular section and S is the permissible working strength of the stainless steel toroid, i. e., 25,000 pounds per square inch.

For an internal working pressure of only 500 pounds per square inch in an expansion joint pipe line of the above specified diameters of pipe line and toroidal bellows, the wall'thickness or gauge of the pipe line would be 0.681 inch, while that of the toroid would be 0.025 inch.

In either case, the gauge of the metal forming the toroid is too tight for practicable butt welding together of two or more parts formed thereof, and it is because of this that welded toroidal elements have heretofore been formed of a gauge much heavier than that actually required to withstand a given internal operating pressure. The hydraulic bulging process of the present invention makes possible utilization of a wall thickness for the toroid which closely approaches the theoretical minimum for the metal of which it is formed when employed for a particular pipe line working pressure, at the same time that it permits formation of a toroidal bellows element having a materially increased working life, it being noted in this latter respect that when the toroid wall thickness is reduced one-half its life expectancy is increased approximately eight times.

' In the hydraulic bulging method-of forming the toroidal-shaped bellows, the cylindrical blank from which it is made is deformed from within without the use of any external restraining dies and as the opposite axially extending tubular sections are integral with the toroid-shaped portion of the bellows, they may be joined to suitable pipe nipples, spacer or supporting elements by suitable welds which are not in an area of flax and, therefore, not restrictive of the flexing life of the bellows. These tubular sections may be secured to embracing pipe elements by resistance seam welding, brazing or even soldering,

the other, with a cylindrical shell or blank I3 therebetween from which the one-piecetoroidalshaped bellows element is made by hydraulic bulging on the press. A threaded nipple I4 having a nut l5 threaded thereon is adjustably supported in opening l6 of upper platen II, the nut I5 being wider than opening it. The nipple I4,

with its vent conduit I'I suitably secured to its upper end, supports atits'lower end a flat annular member I8 just below the platen I I and inside theupper end of blank I3. An annular member I8, positioned with its upper face parallel to the lower face of platen II, is threadedly secured to and supported by the lower end of nipple I4. Thus, the hydraulic pressure fluid, e. g., water, may flow fromthe interior of blank l3 to and-through the vent conduit [1.

The annular member I8 of outside diameter slightly less than the internal diameter of blank I3 is circumferentially undercut on its upper face to provide an annular ledge or seat l9, the walls of which meet preferably at substantially right angles. ledge" I9 in contact with the undersurface of platen II and the inside surface of that-portion of blank I3 extending between the ledge I9 and platen If is a compressible sealing ring at, of rubber or the like,which is adapted, when hydraulic pressure is exerted upon annular member ill, to be compressed to form a water-tight seal between the parts. It will be understood that the sealing ring 20, placed upon member I8 before the latter is threaded upon nipple i4, may be initially compressed after blank I3 is in place bymanually or otherwise turning adjustable nut I5, whereupon further compression by hydraulic action on member l8 will form a water-tight seal at the upper confined'end of the tubular blank I3. A similarly shaped flat annular member 2 I with an annular seat or ledge 22 is fitted with a compressible sealing ring 23 in contact with the inside surface of the lower end of blank I3 and with the upper surface of lower platen I2, so that when hydraulicpressure is exerted upon the upper surface of member 2|, the sealing ring 23 may be Fitting snugly on the annular seat or ;spaced freely between the compressed to form a water-tight seal between the parts. Annular member 2|, spaced from platen |2 to allow for movement thereof in compressing the sealing ring 23, is also fitted'with a conduit nipple 24, the latter being extended freely through a suitable opening 25 provided in the platen l2 and being connected to a conduit 26 for supplying fluid (e. g. water) under pressure into the interior of the tubular blank l3. As in the case of the upper nipple M, the nipple 24 is also provided with a nut I5 for preliminarily drawing the member 2| toward its platen |2 to compress the sealing ring 23 sufliciently to seal the lower end of the tubular blank I3. In accordance with conventional practice the conduit 26 may be provided with suitable valve means (not shown) for exhausting the fluid from the interior of the blank upon completion of the bulging operation of the present invention.

In order to form the toroidal-shaped portion of the bellows element by hydraulic bulging alone, dies in the form of encircling rings 21 and 28 are provided adjacent upper and lower portions of blank l3, those portions of the blank inside the rings forming the oppositely extending axially aligned tubular sections 29 and 30 (Figure 2) of the completed bellows element, while the portion of the blank between the rings forms the toroid-shaped portion 3| (Figure 2) thereof. It will be obvious that the size of the toroid 3| to be formed will depend upon the length of blank |3 extending between the ring dies 21 and 28.

It will be understood that ring dies of such predeterminedlength may be employed as will insure that the completed toroid 3| will be platen-supported members 34 and 35. The ring dies 21 and 28, with their free edges rounded, as at 32 and 33, may be formed as integral extensions of members 34 and 35 which are respectively mounted upon the upper and lower platens II and |2. Preferably, the upper member 34 is secured to the upper platen II in encircling relation with respect to tubular blank l3 by bolts 36 in threaded engagement with the marginal edge of the platen, while in the case of the lower member 35 its own weight is sufiicient to hold it in position upon the lower platen l2 in encircling relation with respect to the tubular blank l3. However, if desired, the lower member 35 may also be bolted to its associated platen l2, in the same manner that the member 34 is bolted to the upper platen Suitably provided in the fill and drain connection 26 is a three-way valve (not shown) by means of which water under suitable pressure may be delivered into the interior of the tubular blank |3 when the bulging operation is commenced, or discharged therefrom when the bulging operation is completed. The vent connection |1 may be suitably provided with a closure valve (not shown) by means of which the blank |3 may be air-vented and by means of which a certain amount of water may be removed from within blank l3 from time to time as the platens II and I2 move toward each other and so compensatefor the resulting reduction in the space therebetween during the bulging operation.

In the operation of the hydraulic press H! with the blank I3 and ringdies 21 and 28 initially in the positions shown in full lines in Figure 1 and with the closure valve of vent |1 opened, a sufficient volume of water to fill blank I3 is delivered into the interior thereof by way of the passages 24 and 25 in communication with the main sup-v ply conduit 26, whereupon the valve in vent I1 is' 21 and 28 l closed and pressure begins to be exerted upon the enclosed water from the pressure supply 26. With opposite circumferential edges of blank l3 in contact with platens and I2, hydraulic pressure upon the flat annular members It! and 2| will cause them to move slightly in opposite directions toward said platens, thereby compressing the sealing rings 20 and 23 to form a watertight seal at each end of the blank l3. When the interior of the tubular blank |3 is thus subjected to hydraulic pressure, the movable platen, which may be either II or l2 but which is, ,here shown as I2, is simultaneously raised toward the fixed platen, here shown as H, and when the pressure exceeds the yield point of the metal of blank |3,- the latter bulges outwardly centrally thereof into its uniformly curved (i. e., circular) form as shown in dotted lines in Figure 1.

It will be noted that the bulging operation is confined between the ring dies 21 and 28, the reversely curved portions 31 and 38 of the toroid which are formed as an incident to the bulging operation being shaped about the rounded free edges of the ring dies. The operation of the press continues to raise platen l2, apply pressure from connection 26, or remove water from within blank I3 by vent l1, as required, to continue the bulging process upon blank |3 until the center thereof has reached its desired outermost diameter. At this point, as shown in Figure 1, the curved section of blank |3 has not assumed its final circular form, this latter form of the bulged portion of the blank being obtained only after the relatively movable platens of the press assume their final positions as shown in Figure 2. It will be noted that as the metal of blank I3 is bulged outwardly it becomes progressively and uniformly thinner from a maximum thickness at the tubular sections 29 and 30 to a minimum thickness at the point of maximum diameter of the toroid section 3|, this spinning being accompanied, however, by a compensating increase in the strength of the metal due to the cold working thereof. Because the hydraulic bulging process applies fluid pressure uniformly against the internal surface of the unconfined portion of the tubular blank l3, such portion is subject to substantially uniform deformation to provide a toroidal section having uniform strength throughout.

The present invention, by the process described, provides a one-piece toroidal-shaped bellows element T with integral oppositely extending axially aligned tubular sections 29 and 30, the toroidalshaped portion 3| thereof being formed entirely by hydraulic bulging without the use of any restraining dies and being connected to each tubular section by the reversely curved portions 31 and 3 8 formed over ring dies 21 and 28. The entire fiexingportion 3| of the bellows element is concave to pressure while the reversely extending portions 31 and 33, which will be adequately supported in the expansion joint by members of the same shape as ring dies 21 and 28, are convex to ressure.

For securing the bellows elements T, formed as above described, in a pipe line, its tubular sections 29 and 30 are respectively provided with oppositely extending tubular members, such as the pipe nipples 39 and 40 shown in Figure 4. These pipe nipples 39 and 40 are respectively provided with rounded circumferential edges 4| and 42 which more or less snugly nest in the reversely curved portions 31 and 38 of each bellows element T, the nipples being secured to the tubular sections 29 and 35 by any convenient form of weld-. ing or brazing. In the case of extremely thin metal resistance seam welding is preferably employed, while with thicker metal the tubular sections 29- and 30 may be joined to pipe nipples 33. and ill by lap welding, shown at altffl interiorly of the nipples. The outer free ends of the pipe nipples as and 48 are adapted to be Welded or otherwise secured directly into a pipe line.

- In one form of expansion joint, as shown in Figure, 5, the sup-porting nipples for the bellows elementare adapted to be bolted into the pipe line andto. this end such nipples each include an axially extending member 3 having its outer free end welded, as at 45, to a bolting flange 4?, the latter being suitably providedwith bolt holes 68. The. bolting flanges ll4l encircle the extra long tubular sections 49-419 of bellows element T, the tubular sections extending beyond the flanges and being turned over the outer faces thereof to provide what is known as a Vanstoned construction. The rounded circumferential free edgesir'all and 5! of pipe sections i lid snugly nest into the reversely curved portions 3? and 38 of the bellows element T, as in the previously described form of the bellows unit.

Figure 6 illustrates still another form of bellows unit constructed in accordance with the present invention. In this form of construction, a plurality of the bellows elements '1 are connected together in axially aligned relation by a series of interconnecting tubular sleeves 52, each of which is of a length at least equal to the combined lengths of a. pair of the adjoining tubular extensions 293i of the bellows elements. As in the case of the pipe nipples 39-438, in each of the connecting sleeves 52 the oppositeends thereof are rounded, as at 53 and 5 1, to snugly fit into the reversely curved portions 3l'33 or" the bellows elements. Any convenient or required number of axially aligned elements T may be joined together in this manner to form a multiple-bellows unit expansion joint. As illustrated in Figure 6, the multiple-bellows unit comprises four toroidalshaped bellows elements '1 joined together by three connector sleeves 52, the oppositely extending tubular end sections 253 and 31] of the end elements having pipe nipples 39 and to secured thereto. In this embodiment, it is preferred that the tubular sections 29 and Eli of the bellows elements be secured to the sleeves 52 and to nipples 3.2 and 523 by resistance welding, each line55 of which is formed or" a series of overlapped spot welds to-provide a fluid tight joint between the welded elements;

The expansion joint shown in Figure 4 as having been made by welding encircling pipe nipples 39 and it to the tubular sections 29 and 35 of a pro-formed toroidal-shaped bellows element may be constructed in another way. As illustrated in Figure 3, a blank 13 of cylindrical form with encircling pipe nipples 3 and is welded, as at idill, to opposite ends thereof may be positioned in the hydraulic press l6 between its plat ens l I and I2 in a manner similar to that shown and described in Figure 1. Inasmuch as the blank from which the expansion joint of Figure 4 is to be formed comprises the cylindrical shell l3 and the nipples li and to welded to the ends thereof, the latter may be employed in themselves as the forming dies about which the bulging of the shell takes place. Thus, except for the fact that the nipples 391 and ie replace the ring dies 2'! and 28, the operation illustrated in Figure 3 is similar to that ofrFi ure 1, the hydraulic pressbeingmodified. only in that the annular members 51 and,

58' thereof as employed in Figure 3 are centrally apertured to diameters sufiicient to embrace thev nipples 39 and 40.

It is within the scope of the present invention to provide a one-piece bellows element S having a pair of axially spaced toroidal sections 3 I 3 I as shown in Figure 8, such element being formed from a blanking member 59 as shown in Figure 7 by the hydraulic bulging process of the present invention. The blanking member 59 is similar to shell blank l3, except that it is longer and is provided with a centrally located encircling member 60 suitably welded thereto. This member 59 is positioned in the hydraulic press H1 in exactly the same manner as blank It with the exception that platens H; and I2 are spaced the required distance apart to receive the longer blank. The embracing sleeve member 60: may be secured to the tubular shell 59 in any suitable manner, as by spot welds 6! or it may be free from the shell, in which case the sleeve 60 is supported centrally of blank shell'59 by any suitable external means until initial bulging of shell 59 above and below the sleeve member Bil operate to hold the same in place. In the present instance, guide die rings 2'1 and 28 and opposite rounded circumferential edges of the sleeve to are the means about which the axially aligned toroid-shaped portions 3 l '-3.i are bulged in the hydraulic press Ill, the reversely extenmng curved sections fil -3 8* being formed by the rounded edges of the ring dies 2'! and 28. The double. toroid-shaped portions 3l ill of bellows element S are joined together by the intermediate tubular section 62 of the blank 59' em braced by the sleeve member till the opposite ends of which fit into the reversely curved sections E3-G3 of the shell, the latter sections be-. ing respectively formed by the opposite rounded ends ti k-E54. of the sleeve 6!]. Tubular sections 29 and 36 axially aligned with eachother and with tubular section 62 are integrally formed with the toroid-shaped sections 3l 3i and extend in opposite directions from the outer sides of each, being respectively joined thereto by the outer reverse curved sections 37* and 33 In order to support the doublev toroid element S for use. in a pipe line, pipe nipples similar to, those designated by the reference numerals 39and 4B in Figure 4 may be secured to the tubular end sections 29 and 38 of the bellows by welding, brazing or the like.

It' will be apparent that by securing a plurality of sleeve members to to the member 59 in suitably spaced relation, a one-piece bellows 918- ment having a plurality of axially spaced toroidal elements may be formed in a single hydraulic bulging operation, the member of such toroidal elements exceeding by one. the number of inter: mediate sleeve members .80 preliminarily secured to the tube 59k Thus, instead of forming. a bellows element with only two toroidal elements as in Figure 8, a bellows element may be formed withthree or any greater number of such toroidal elements.

It will be understood, of course, that the present invention is susceptible of various changes and modifications which may be made from time to time without departing from the general principles or real spirit thereof, and it..is accordingly intended to claim the same broadly, as wellas specifically, as indicated by the appended claims.

What is claimed as newv and usefulis:

1. The process of forming fromaround tubular blank a one-piece. bellows. element having 9 axially spaced portions and an intermediate annularly corrugated portion including the step of the interior of said blank, the step of confining axially spaced portions of said blank respectively within axially spaced and coaxially alined annular members rounded on the circumferential edges thereof which face each other, the step of filling the sealed interior of said blank with a substantially incompressible free-flowing material under pressure sufficient for bulging the intermediate portion of said blank to afford an annular corrugation, said intermediate portion being unconfined against outward deformation during said bulging process, the step of subjecting said blank to axially applied pressure sufficient to cause said spaced portions of the blank to move axially toward one another in aid of said bulging process, said movement being suificient to impart to a radial section through a segment of the fully formed corrugated portion of the blank a shape characterized by an outer part in the form of the major segment of a circle and a pair of inner parts reversely curved relative to said outer part, said outer part being joined by said reversely curved parts to said spaced portions of n the blank, and the step of limiting increase in the bulging pressure by reducing as required the amount of said material within said blank as the capacity of the latter changes by reason of said relative axia1 movement of the spaced portions of the blank.

2. The process of forming from a round tubular blank a one-piece bellows element having axially spaced portions and an intermediate annularly corrugated portion including the step of sealing the interior of said blank, the step of confining axially spaced portions of said blank respectively within axially spaced and coaxi-ally alined annular members rounded on the circumferential edges thereof which face each other, the step of subjecting said sealed interior to hydraulic pressure sufiicient for bulging the intermediate portion of said blank to afford an annular corrugation, said intermediate portion being unconfined against outward deformation during said bulging process, the stepof subjecting said blank to axially applied pressure suificient tocause said spaced portions of the blank to move axially toward one another in aid of said bulging process, said movement being suificient to impart to a radial section through a segment of the fully formed corrugated portion of the blank a shape characterized by an outer part in the form of the major segment of a circle and a pair of inner parts reversely curved relative to said outer part, said outer part being joined by said reversely curved parts to said spaced portions of the blank, and the step of draining some of the pressure medium from said sealed interior of the blank to afford said relative axial movement of the spaced portions of the blank without excessive increase in the bulging pressure.

3. The process of forming from a round tubular blank a one-piece bellows element having axially spaced portions and an intermediate annularly corrugated portion including the step of sealing the interior of said blank, the step of encircling axially spaced portions of said blank with die rings rounded on the circumferential edges facing each other, the step of subjecting said sealed interior to hydraulic pressure sufficient for bulging th intermediate portion of said blank to afford an annular corrugation, said intermediate portion being unconfined against outward deformation during said bulging process, the step of moving said die rings toward one another in aid of said bulging process, said movement being sufiicient to impart to a radial section through a segment of the fully formed corrugated portion of the blank a shape characterized by an outer part in the form of the major segment of a circle and a pair of inner parts reversely curved relative to said outer parts, said outer part being joined by said reversely curved parts to said spaced portions of the blank, and said reversely curved parts being formed about said rounded edges of the die rings, and the step of draining some of the pressure medium from said sealed interior of the blank to afford said movement of the die rings without excessive increase in the bulging pressure.

JAMES P. ZALLEA.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 335,371 Major Feb. 2, 1886 349,718 Hollerith et a1. Sept. 28, 1886 773,046 Bayles Oct. 25, 1904 788,119 Pope Apr. 25, 1905 1,754,922 Weldon Apr. 15, 1930 2,106,495 Debor Jan. 25, 1938 2,352,038 Tolke June 20, 1944 2,341,002 Vollrath Feb. 8, 1944 2,372,917 Tuttle Apr. 3, 1945 FOREIGN PATENTS Number Country Date 9,889 Great Britain of 1900 122,762 Germany of 1901 

